Abstract: In accordance with the present invention, a power conductor rail structure is provided using a multi-metallic construction. The composite rail of the invention includes an asymmetrical steel portion having a top flange thickness greater than that of the bottom flange in a generally I-shaped configuration with spaced apertures along the length of the web. Aluminum cladding is cast onto both sides of the web with a cold rolled high conductivity layer, such as copper disposed between the aluminum and steel on either side of the web and having holes corresponding in size and shape to the apertures of the web. The aluminum cladding extends through the web apertures producing a multi-metallic sandwich construction. The high conductivity layers provide a mechanical bond between the steel and aluminum and reduces transfer resistance and increasing overall conductivity.

Abstract: In accordance with the present invention, a power conductor rail structure is provided using a multi-metallic construction. The composite rail of the invention includes an asymmetrical steel portion having a top flange thickness greater than that of the bottom flange in a generally I-shaped configuration with spaced apertures along the length of the web. Aluminum cladding is cast onto both sides of the web with a cold rolled high conductivity layer, such as copper disposed between the aluminum and steel on either side of the web and having holes corresponding in size and shape to the apertures of the web. The aluminum cladding extends through the web apertures producing a multi-metallic sandwich construction. The high conductivity layers provide a mechanical bond between the steel and aluminum and reduces transfer resistance and increasing overall conductivity.

Abstract: A linear thermal expansion joint between two sections of power conductor rail formed of steel web and aluminum cladding about the web, each rail section longitudinally and vertically halved at the rail end through the center of the steel web creating a mating surface of selected expansion length. Each rail end includes an elongated slot and a guide block secured to the aluminum cladding and extending through the slot. The rail ends are slidingly secured together with bolts and spring washers on the guide blocks so that the rail ends overlap side by side with the mating surfaces facing each other sandwiching a brass slide plate which facilities longitudinal movement between the rail sections. Exposed ends of the rail contact surfaces are chamfered to eliminate snags or sharp surfaces and to compensate for small dimensional differences between rail sections during alignment and assembly of the expansion joint.